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Analysis

Integrating QC-CALC and Process Toolbox

This white paper discusses integrating QC-CALC with Process Toolbox by Becker Quality Solutions, Inc. and the solution that the Process Toolbox can provide.

The Manual Input screen gives you an interface to enter extra data (dimensions or factors) into a file that already contains the data from the CMM. Normally a CMM automatically measures a part and sends the data over to QC-CALC to be analyzed and displayed. Now, what if, in addition to automatic part checks, you have to check parts with a different machine or by hand? The Manual Input screen gives you the ability to enter these values into the same file as the CMM data.

HyperTerminal is a simple program that listens to and displays any data
that comes in through a COM Port. This is a great way to troubleshoot gages and
the software that reads them. The first thing that you want to make sure of is
that your gage is actually working. Once you know your gage is working
correctly then you can interface to QC-Gage. This White Paper provides directions for downloading the HyperTerminal program from the Prolink website.

It seems like you have all settings correct but the graphs still aren't changing? There are a couple of things that could be an issue here: It is possible that your inspection software isn't actually creating the communication file(s) that QC-CALC Real-Time expects or the communication file(s) being created may have a different format inside the file (meaning QC-CALC Real-Time doesn't understand the data in there and throws it away). The steps here will help figure out where the data collection process is breaking down.

As data is being collected a warning will appear in the Status area when there is only space for 10 or less records remaining. In many cases this message is ignored, but, if it wasn’t, it clearly states that the database is almost full. In this case the file needs to be fixed before 7 more parts are received or new data will be lost. These directions explain how to adjust existing files and any new files that are created.

This white paper explains flip fixtures using OGP MeasureMind and MeasureX. The need for flip fixtures occurs when you have several parts in a fixture and you need to measure more than one side of each part. Since the camera only looks down, you have multiple routines to measure each side of each part in the fixture. Since you have multiple routines in OGP, you will end up with multiple QCC files in QC-CALC. Using built-in functionality in QC-CALC, you can set it up so the data is automatically combined from multiple routines. This allows you to see it all in the same QCC file.

This
white paper explains flip fixtures using Micro-Vu Inspec.
The need for flip fixtures occurs when you have several parts in a
fixture and you need to measure more than one side of each part. Since
the camera only looks down, you have multiple routines
to measure each
side of each part in the fixture. Since you have multiple routines
in Inspec, you will end up with multiple QCC files in QC-CALC. Using built-in
functionality in QC-CALC, you can set it up so the data is automatically
combined from multiple routines. This allows you to see it all in the
same QCC file.

As new records are collected you can automatically create a copy of these records in an Archive file. This can be done for backup purposes, or it can be useful if the amount of data being collected into a single .qcc file grows quickly and makes the normal operation of QC-CALC Real-Time slower.

Occasionally you may need to capture output from a gage in order to
troubleshoot an existing connection or to define a new gage interface.
Regardless of the reason you need to capture data, Windows provides
tools that allow you to connect to a serial port via RS232.

Since the release of Calypso 3.8.xx or higher, we have witnessed occasional error messages at the end of a part run. When Calypso completes the part inspection it creates the table files that QC-CALC Real-Time reads. QC-CALC then deletes the table files which randomly upsets Calypso and produces a "File does not exist" error.

There are times QC-CALC Receives a different number of dimensions from the inspection machine than expected (when the .qcc file was originally created it had 10 dimensions, the last part received only had 8 dimensions) and QC-CALC needs to know how to handle this occurrence. The different choices available are explained in this area.

QC-CALC can export inspection results from its database to Q-DAS formatted files. The raw inspection results are saved in .DFX files while the nominals & tolerances and extra trace data (non-measurement data) are stored in.DFD files. These two files make up the Q-DAS inspection results file that is read into the qs-STAT program. This section of the manual discusses the method of exporting QC-CALC data in Q-DAS format.

To reduce the number of plots shown in the Real-Time screen QC-CALC uses the concept of a dimension selector or filter. This is a manual operation where a list of your features is displayed and you highlight the dimension you want to see. During file creation, QC-CALC automatically selects all dimensions by default. To view the dimension selector, choose menus View – Dimensions to Plot.

A Gage Repeatability
and Reproducibility Study is a method of determining the suitability of a gage
or gauging system for measuring a particular process. This article describes the correct way to set up a Gage R&R Study and what the report means when finished.

It is very easy to accidentally set up Dimension and Record Filters so they only get data from the very latest model of your Part File. When this happens you do not get the data you expect (or maybe you don’t get any data at all). This White Paper gives directions for changing/creating your Dimension and Record Filters so all data will be returned and also gives instructions for making Data Groups determine the Part Files and Dimensions to use more dynamically.

Many of Enterprise Report Scheduler’s features revolve around the ability to develop and customize reports and dashboards based on individualized settings from one or many users connected to the same database. This White Paper will introduce you to many of the concepts that will help you best utilize the software.

Many
users experience problems with mapped network drives. The mapped drives do not
reconnect correctly after a reboot even when the Reconnect at logon option was set during the mapping of the drive.
This
White Paper provides the steps needed for creating this batch file to
disconnect and reconnect the mapped drive and for running this batch file from
Windows Task Scheduler.

The File - Modify Database Structure menu provides a tool to change the
structure and content of any database previously created. QC-CALC
automatically builds its database when it reads a never before seen “results file”
from your CMM. Since QC-CALC has a policy of not asking questions, it must
obtain reasonable answers from somewhere. The File Creation
Defaults that QC-CALC uses may change over time and the older files will need to be adapted manually to follow these changes.

There are times machine data ends up in separate .qcc files (mostly due to receiving a different number of dimensions than expected when data collection happens) and you want to get all data into a single file. This article describes the method for doing this process.

Historically, QC-CALC Real-Time has been used within an individual inspection machine as a single copy of software. Each person controlled and adjusted QC-CALC’s operation individually. As networks became more prevalent, the inspection devices were connected to the network making data movement easier. This created the need to control the individual copies of QC-CALC running throughout the shop from a central location.

As of QC-CALC version 3.2, an Administrative Tool was added to help the Quality Department set up and control every copy of QC-CALC within the entire company. This tool can be activated and used from any of the QC-CALC copies on the network.

In addition, the medical supply companies must satisfy FDA title 21 Code of Federal Regulations (21 CFR Part 11) Electronic Records; Electronic Signatures, as it applies in a medical manufacturing environment. A special section has been added to this document which describes how QC-CALC can be configured to help you meet the requirements of Part 11.

Are you running parts without an operator present and need to have someone notified when a part is Out of Specification? There are two ways to email an operator from QC-CALC Real-Time when a part is Out of Specification; through Automatic Report or through Trend Analysis. The step-by-step directions for setting up both of these methods are discussed here so you can choose the method that works the best for you.

If you wanted to run a single report on multiple QCC files all at once we offer a feature called Grouping. It happens to only be available in QC-CALC SPC, this white paper reviews how to create, modify, and delete groups in QC-CALC SPC.

Viewing Real-Time SPC charts in multiple locations can be very useful. This article explains how QC-CALC SPC can be used to show Real-Time charts in the office, shop, or wherever you need immediate feedback - a real paper saver!!

In order for Prolink products to run correctly the user currently logged in to the computer must have Read/Write access to 1 section of the registry along with the directory that the program is installed in. This document shows the specific instructions for giving the necessary permissions to both of those areas.

The default Raw Data reports that come with ERS do not show any factor values in the heading area of the report. The reason for this is the factor values should, in theory, be different for each row of the table which makes it difficult to show any single value in the header. This White Paper will give step by step instructions for designing your own custom template and adding the first Text and Numeric Factor values from the first record displayed to the header area of one of the standard Raw Data templates.

One of the default Raw Data reports that is shipped with ERS has a column for Text Factor 1 in the table. This White Paper will give step by step instructions for designing your own custom template and changing the Text Factor 1 value in the table to Numeric Factor 1.

The Stat Summary report that comes with QC-CALC only displays columns for some statistical values, but there are other values available to be displayed. This White Paper will give step by step instructions for customizing the default template and changing the "Sigma" column to show the "Percent Out of Spec" instead.

The default Raw Data report (DataStat.raw) that come with QC-CALC shows the Pp and Ppk values in the calculations area. This White Paper will give step by step instructions for changing those rows to show Cp and Cpk instead (using the estimated Sigma).

With the 3.4 version of QC-CALC the variables and fields within the Raw Data report were changed and if you attempt to run a template from a previous version of QC-CALC an error will appear. This means any Raw Data templates from previous versions of QC-CALC that had been customized will no longer run once you upgrade to the 3.4 version. We have provided a program to convert these templates for you and these directions should be used to update your templates.

Note: Only Raw Data templates were changed, so all other templates do not need this converter.

The default Plot
Reports show the Ppk value, but it is possible to change them so the Cpk value is
shown instead. This document gives step-by-step directions for changing from a
Ppk value to a Cpk value in the default 1x2 Plot Report template.

The default Raw Data reports that come with QC-CALC may not show as many columns of data as you need. This White Paper will give step by step instructions for designing your own custom template and adding another column of data to one of the standard Raw Data templates.

The default Cpk – Process Capability report does not show any Factor values, but it is possible to add those values into the template starting with revision 3.4.88. This document gives step-by-step directions for inserting a Text Factor into the default Cpk – Process Capability Mulitple Plots template.

The default First Article report that comes with QC-CALC does not display the Dimension Source value. This White Paper will give step by step instructions for adding a column to the default First Article template to display the Dimension Source.

This White Paper gives step-by-step instructions for designing your own custom template and adding the words “PASS” or “FAIL” to the header area of the standard First Article template. The PASS/FAIL item will be based on the Number of Fails = 0 (no dimension were out of specification = “PASS”) or the Number of Fails > 0 (at least 1 dimension was out of specification = “FAIL”).

The default Raw Data reports that come with QC-CALC show the Out of Specification points in red along with ** before the Out of Spec value. You may want to differentiate between a value being Out of Spec on the high side or the low side by showing different colors. This White Paper will give step by step instructions to show Out of Spec High values in Red and Out of Spec Low values in Yellow.

A previous White Paper discussed having the Actual value rounded to the specified precision for that dimension before the testing for that value being Out of Specification. Once the testing of the Actual values is changed, it is possible the Reject Count that can be shown in the footer will no longer match up with the values shown in red (out of spec). This White Paper will give step by step instructions for adding the Reject count line in the footer and having those values based on Rounded values also.

The default Raw Data reports that come with QC-CALC show the Out of Specification points in red along with ** before the Out of Spec value. To determine which values should be red and marked with ** the full precision of the Actual value stored in the QC-CALC database is tested, but you may prefer to have the Actual value rounded to the specified precision for that dimension before the testing happens. This White Paper will give step by step instructions to change the testing to
rounded values for both the red font color and the ** before the value.

In the 3.2 version of SmartReport powered by QC-CALC the output sent from the inspection software to QC-CALC via the Report output is saved into a .qcc file with “_report” added to the file name. You may not want that “_Report” to appear in your reports so this White Paper gives step by step instructions for changing the default OnePiece.fst file to remove that portion of the file name.

Changing Out of Specification Testing in the Raw Data Report(login necessary)

The default Raw Data reports that come with QC-CALC show the Out of Specification points in red along with ** before the out of spec value. This White Paper gives step by step instructions for changing the red font to Bold and removing the ** before the value.

The Raw Data with Stats report that comes with QC-CALC only displays rows for some statistical values, but there are other values available to be displayed. This White Paper will give step by step instructions for designing your own custom template and adding a row of Fail Counts to the Raw Data with Statistics standard template.

The default Raw Data
reports that come with QC-CALC only show rows for the Feature Labels, Nominals,
Tolerances, and the actual data values. This White Paper will give step by step
instructions for designing your own custom template and adding a row of Dimension
Sources to one of the Raw Data standard templates.

The default First Article – Multiple Parts reports that come with QC-CALC only show 5 parts. This White Paper will give step by step instructions for designing your own custom template and adding a 6th part column to one of the First Article – Multiple Parts standard templates.

The default XBar and Range report does not show the Cpk value, but it is possible to add that value into the template. This document gives step by step directions for inserting the Cpk value into the default XBar and Range full page template. These same general instructions can be used for inserting other values into reports also.

The default Raw Data reports that come with QC-CALC do not show any factor values in the heading area of the report. The reason for this is because the factor values should, in theory, be different for each row of the table making it difficult to show any single value in the header. This White Paper will give step by step instructions for designing your own custom template and adding the Text Factor 1 value from the first record displayed to the header area of one of the standard Raw Data templates.

There are times you would like to have values entered into your reports but you do not need those values stored with your data. Commands can be added within your template to collect typed values at run-time. There are two ways to be asked for this information (type the value into the Print Preview screen or have a question pop up and wait for an answer) and both methods will be covered in this White Paper.

The default Raw Data reports that come with QC-CALC do not show any columns of factor values to start. This White Paper gives step by step instructions for designing your own custom template and adding a column of Text Factor 1 values to one of the Raw Data standard templates.

There are several locations where QC-CALC calculates the control limits as well as other limits. Each area is summarized in this section to help you identify the best method of achieving the limits you expect under the conditions you want. QC-CALC can make these calculations for you either manually or automatically and on one dimension or on all dimensions.